Mold top insulating assembly and method of use

ABSTRACT

An ingot mold top comprising a base having a pair of side walls, each side wall having a first end and a second end, each of the first ends terminating in an angled portion and the second ends connected by a first end wall, a wedge having an end wall and a pair of side walls, the pair of side walls extending generally perpendicularly away from the end wall, and wherein the wedge pair of side walls each terminate in an angled portion and the base and wedge completely encompass an interior periphery of a mold.

BACKGROUND OF THE INVENTION

1. Technical Field

The invention relates generally to mold top insulating assemblies andexothermic assemblies. More particularly, the invention relates to asafer and easily installed mold top. Specifically, the invention relatesto a multiple piece mold top assembly which can be safely installed withan alignment device and provide an increased usable ingot yield.

2. Background Information

The use of a mold top in casting metal has been common place fornumerous years. Traditionally, a mold top is used to insulate the moltenmetal and maintain a more constant temperature during the solidificationprocess. The constant temperature provides a more consistent materialwith fewer contaminants.

Mold tops, or “hot tops”, have varying heights and dimensions.Initially, the mold top is sized and shaped to fit the mold and extendsfrom the top of the mold only the distance necessary to provideconsistent cooling for the molten metal. Originally, mold tops were atwo-piece assembly with the base installed first and the top located onthe base after the molten was poured.

FIGS. 1 and 2 illustrate a pair of three and four piece, respectively,mold tops with wedging side walls. The prior art mold top in FIG. 1 usesa pair of angled side walls to ensure that the mold top base is securelyheld in place and located at the extreme interior periphery of the mold.The FIG. 1 mold top suffers from numerous shortcomings, including thefact that two side walls must be installed. Since the two side wallswill each move the mold top in opposing directions, the side walls mustbe installed simultaneously, requiring two people working together, orthe installer must fight to install the second side wall as the firstattempts to move out of place. Yet another shortcoming of the FIG. 1mold top is that it requires the operator to stand over the mold inorder to install both side walls. Although one side wall may be locatedclose to the working edge of the ledge, the second end will be on theopposite side. Thus, the installer is required to stand over the moldwhich is very dangerous and not practical.

The mold top of FIG. 2 is used for installation of round molds. Althoughthe round mold has advantages over the two-piece base of FIG. 1, theround mold top still suffers from shortcomings. In particular, the roundmold top is difficult to place perfectly centered along the extremeinterior periphery. While having only one angled side wall prevents theinstaller from having to step over the mold, it is much more difficultfor the installer to provide a force tangential to the mold top so thatthe side wall opposite the angled side wall is located proximate theinterior periphery.

Thus there is a long-felt need in the art for a mold top which caneasily and safely be installed in a mold by a single installer andprovides a higher usable yield of material.

SUMMARY OF THE INVENTION

The present invention broadly comprises an ingot mold top comprising abase having a pair of side walls, each side wall having a first end anda second end, each of the first ends terminating in an angled portionand the second ends connected by a first end wall, a wedge having an endwall and a pair of side walls, the pair of side walls extendinggenerally perpendicularly away from the end wall, and wherein the wedgepair of side walls each terminate in an angled portion and the base andwedge completely encompass an interior periphery of a mold.

The present invention further broadly comprises a method of installingan ingot mold top comprising the steps of inserting a mold top basehaving a pair of side walls with angled terminating portions within amold, locating a mold top wedge at least partially between the base andthe mold, and forcing the wedge downwards to provide axial movement in adirection along the angled terminating portions.

BRIEF DESCRIPTION OF THE DRAWINGS

The preferred embodiment of the invention, illustrative of the bestmodes in which Applicant has contemplated applying the principles of theinvention, are set forth in the following description and are shown inthe drawings.

FIG. 1 is a perspective view of a prior art mold top with two opposingangled side walls;

FIG. 2 is a perspective view of a prior art mold top for a round moldwith a single angled side wall;

FIG. 3 is a perspective view of three molds and a preferred embodimentmold top;

FIG. 4 is an exploded perspective view of a preferred embodiment moldtop of the present invention;

FIG. 5 is a top plan view of a preferred embodiment mold top wedge ofthe present invention;

FIG. 6 is a top plan view of a preferred embodiment mold top base of thepresent invention;

FIG. 7 is a right plan view of a preferred embodiment mold top lid ofthe present invention;

FIG. 8 is a right plan view of a preferred embodiment mold top wedge ofthe present invention;

FIG. 9 is a right plan view of a preferred embodiment mold top base ofthe present invention;

FIG. 10 is a perspective view of a preferred embodiment alignment deviceof the present invention;

FIG. 11 is a perspective view of a person installing a preferredembodiment mold top base within the mold;

FIG. 12 is a perspective view of a preferred embodiment mold top baselocated within the mold;

FIG. 13 is a perspective view of a person installing a preferredembodiment mold top wedge;

FIG. 14 is a cross-sectional view of a preferred embodiment mold topwedge being installed;

FIG. 15 is a perspective view of a person installing a preferredembodiment mold top wedge with a preferred embodiment alignment device;

FIG. 16 is a cross-sectional view of a preferred embodiment mold wedgebeing installed with a preferred embodiment alignment device;

FIG. 17 is a front plan view of a preferred embodiment mold top wedgebeing installed with a preferred embodiment alignment device;

FIG. 18 is a perspective view of a person installing a preferredembodiment mold top wedge with a preferred embodiment alignment deviceby providing a downward force on the alignment device;

FIG. 19 is a cross-sectional view of a preferred embodiment mold topinstalled within the mold;

FIG. 20 is a perspective view of a person removing a preferredembodiment alignment device after installing a preferred embodiment moldtop wedge;

FIG. 21 is a perspective view of molten metal being poured into a moldwith a preferred embodiment mold top installed.

FIG. 22 is a cross-sectional view of molten metal in a mold with apreferred embodiment mold top installed;

FIG. 23 is perspective view of a person installing a preferredembodiment mold top lid;

FIG. 24 is a perspective view of a preferred embodiment mold top lidpartially installed;

FIG. 25 is cross-sectional view of a preferred embodiment mold top lidpartially installed;

FIG. 26 is a perspective view of a person pushing a preferred embodimentmold top lid towards the far end of the mold top;

FIG. 27 is a perspective view of a preferred embodiment mold top withthe lid completely installed; and,

FIG. 28 is a cross-sectional view of a preferred embodiment mold topwith the lid completely installed.

DESCRIPTION OF THE PREFERRED EMBODIMENT

At the outset, it should be appreciated that like drawing numbers ondifferent drawing views identify identical, or functionally similar,structural elements of the invention. While the present invention isdescribed with respect to what is presently considered to be thepreferred embodiment, it is to be understood that the invention asclaimed is not limited to the disclosed aspects.

Unless defined otherwise, all technical and scientific terms used hereinhave the same meaning as commonly understood to one of ordinary skill inthe art to which this invention belongs. Although any methods, devicesor materials similar or equivalent to those described herein can be usedin the practice or testing of the invention, the preferred methods,devices, and materials are now described.

The mold top assembly of the present invention is indicated generally at30, as is particularly shown in FIGS. 1 through 28 sitting on a platform32, shown with the components separated.

As seen in FIG. 3, mold top assembly 30 generally includes a base 34, awedge 36, and a lid 38. Platform 32 is preferably located close to molds40 so that the operator can easily locate the mold top assembly withinthe mold. Each mold preferably has a distal end 41 and a proximate end43. In particular, mold top assembly 30 is placed on sidewalls 42 andwithin an opening 44 formed by the sidewalls. Thus, the mold topassembly is shaped complimentary to the opening of the molds, which isgenerally rectangular in a preferred embodiment.

FIGS. 4 through 9 illustrate various views of mold top assembly 30. Base34 includes a first side wall 46, a second side wall 48, and a first endwall 50. First side wall 46 and second side wall 48 are preferablyparallel to each other and spaced apart by first end wall 50. An end 52of first side wall 46 opposite first end wall 50 terminates in an angledportion, while an end 54 of second side wall 48 opposite first end wall50 terminates in an angled portion. The angled portions extend along theend parallel to first end wall 50 and the distance from the first endwall to the ends (52 and 54) increases from top to bottom, or in otherwords, the end walls are angled. Although the ends may have any suitableangle, a preferred embodiment angle is in the range of approximately 5to 45 degrees.

Base 34 also includes a shoulder 56 attached to the exterior periphery,which may be formed integral to the base in a preferred embodiment.Shoulder 56 forms the top surface of the base, as well as extendsoutward of the first side wall, the second side wall, and the first endwall. Since the shoulder extends outwards of the remainder of the base,the bottom side of shoulder 56 rests on the top of mold sidewall 42.

Further, base 34 includes a ledge 58 attached to the interior periphery,which may be formed integral to the base in a preferred embodiment.Ledge 58 extends outward from the upper portion of the first side wall,the second side wall, and the first end wall. Ledge 58 may be formed bylocating shoulder 56 partially outward of the side walls and end wall ofbase 34. Advantageously, ledge 58 provides a locating and holding areafor lid 38, as will be described in greater detail below.

As seen in FIGS. 4 and 5, wedge 36 includes an end wall 60, a first sidewall 62, and a second side wall 64. First side wall 62 and second sidewall 64 are preferably arranged generally parallel to one another andseparated by end wall 60. Further, first side wall 62 terminates in anangled portion 66, while second side wall 64 terminates in an angledportion 68.

In accordance with one of the main features of the present invention,first side wall 62 and second side wall 64 extend away from end wall 60a sufficient distance to allow an angled portion that is complimentaryto ends 52 and 54 respectively. In particular, the angled portions offirst side wall 62 and second side wall 64 are preferably in the samerange as ends 52 and 54, namely 5 to 45 degrees. However, it should beimmediately apparent to one of ordinary skill in that art that almostany angle would be sufficient.

FIG. 8 illustrates a side profile view of a preferred embodiment ofwedge 36, while FIG. 9 illustrates a side profile view of a preferredembodiment of base 34. As can be seen, wedge 36 is preferably the sameheight as base 34. In addition, base ends (52 and 54) and angledportions (66 and 68) are complimentary shaped to each other to provide avertical sliding engagement that yields a horizontal movement in base34.

FIGS. 4 and 7 illustrate lid 38, which is sized and shaped to fit withinthe assembled combination of base 34 and wedge 36. Specifically, lid 38preferably has a thickness T approximately equal to the distance betweenledge 58 and the top of shoulder 56. Advantageously, this allows the lidto fit securely along ledge 58 without the possibility of lid 38 easilyfailing off. Further, when wedge 36 is fully seated, a top side 70 ofthe wedge is located on approximately the same plane as shoulder 56 andlid 38 fits between base 34 and wedge 36.

Base 34, wedge 36, and lid 38 are all preferably composed of a heatresilient material such as a ceramic composite or ceramic fiber, howeverany suitable material which can reduce impurities in the ingot head andstill be located within the mold opening as detailed below may be usedand is within the spirit and scope of the invention as claimed.

Having described the structure of a preferred embodiment of the mold topassembly, a preferred mold top installation device 72 will now bedescribed in detail and should be viewed in light of FIG. 10. FIGS. 15through 20 illustrate an installation process with the device and willbe described with the full installation procedure of the mold topassembly.

Installation device 72 includes tube 74 with an inner rod 76 movableaxially within tube 74. Tube 74 terminates in first end 78 and inner rod76 terminates in second end 80. A guide 82 is attached at each end (78and 80), each guide includes a central member 84 arranged generallyperpendicular to tube 74 and generally parallel to side walls 46 and 48of base 34 during operation. Further, an angled member 86 extends fromboth the top and bottom of central member 84. Each angled member ispreferably directed back towards tube 74. Advantageously, the angledmembers help to locate and center the installation device, as well asspread base 34 apart in order to facilitate installation of wedge 36. Inparticular, the gradual increase in distance between the angled membersallows the installation device to more easily slide between side walls46 and 48 of base 34 since there is less contact at the guides.

The installation device also includes an arm 88 and a driving bar 90.The driving bar is spaced apart from tube 74 by the generally L-shapedarm 88 in a preferred embodiment. In particular, the driving bar remainsparallel to tube 74, but the driving bar is offset from tube 74 bothvertically and horizontally. Driving bar 90 is preferably rectangular inshape, with the widest end directed upwards so that the installer canstrike the face to urge the installation device and wedge 36 downwards.

Having described the structure of the a preferred embodiment of the moldtop assembly and installation device, a preferred method of installing amold top assembly will now be described in detail and should be viewedin light of FIGS. 11 through 28.

FIGS. 11 and 12 illustrate an installer locating base 34 within moldopening 44. The installer preferably picks up and handles base 34 by theopen end and leads with first end wall 50. Base 34 is then insertedwithin opening 44 such that end wall 50 is adjacent distal end 41 of themold and first wall end 52 and second wall end 54 are located nearproximate end 43 of the mold. As described above, shoulder 56 rests onside walls 42 of the mold.

As seen in FIGS. 13 and 14, the installer then locates wedge 36 within agap 92 formed by proximate end 43 of the mold and base 34. A lower endof wedge 36 is inserted within gap 92 first in order to properly alignangled portions 66 and 68 of wedge 36 with ends 52 and 54 of base 34. Asparticularly seen in FIG. 14, after partially installing wedge 36, theinstaller pushes on top side 70 in the direction associated with arrow94 until the wedge is at least partially installed within the mold.

FIGS. 15, 16, and 17 illustrate the use of installation device 72 toseat wedge 36 within the mold. Next, the installer locates top side 70of wedge 36 proximate the bottom side of driving bar 90. Since wedge 36is partially located within gap 92, guides 82 are arranged proximate theinterior periphery of base first side wall 46 and base second side wall48.

FIG. 17 is an endwise view of the installation device being used tolocate wedge 36 and illustrates how guides 82 and specifically centralmembers 84 maintain the distance between the first and second side wallsof base 34. Further, it should be noted that angled members 86 alsooperate to ensure proper alignment of the installation device, as theangled members tend to urge the guides into alignment with one anotherdue to the consistent angled wall at each guide.

Averting to FIGS. 18 and 19, the installer then uses a mallet or othersolid object to provide a force in the direction associated with arrow96 on driving bar 90 until the wedge is fully seated between base 34 andproximate end 43 of mold 40. The force in the direction associated witharrow 96 directs wedge 36 downwards and the interaction between wedge 36and base 34 at angled portions 66 and 68 translates a portion of theforce into an axial force in the direction associated with arrow 98. Inparticular, the complimentary shaped angled ends of base 34 and wedge 36moves base 34 in the direction associated with arrow 98 and forces firstend wall 50 to a position adjacent distal end 41.

The next step is seen in FIG. 20, where the installer removes theinstallation device by pulling upwards in the direction associated witharrow 100. Advantageously, angled members 86 help to ease removal of theinstallation device from the mold top assembly in the same manner asangled members 86 assisted in the installation.

Next, as seen in FIGS. 21 and 22, molten metal 102 is poured into themold until the top of the molten metal is still below shoulder 56. In apreferred embodiment, top pouring is utilized, however it should beimmediately apparent to one of ordinary skill in the art that bottompouring may be incorporated without departing from the spirit and scopeof the present invention as claimed.

Averting to FIGS. 23-28, the final step is installing lid 38. Theinstaller locates one end of lid 38 on ledge 58, as seen in FIGS. 24 and25. Next, lid 38 is moved in the direction associated with arrow 104 andthe end of lid 38 slides along ledge 58 until the end is locatedproximate distal end 41. Further, the installer may use a pushing rod106 or other similarly situated tool to help move the lid into place.Rod 106 is helpful due to the gap between mold 40 and platform 32. Asspecifically seen in FIGS. 27 and 28, in the full installed position,lid 38 rests on ledge 58 and abuts wedge 36. Further, the combination ofbase 34, wedge 36, and lid 38 provide a sealed mold top assembly thatcan easily and efficiently be installed within a mold by a single personwhile minimizing potential danger.

Accordingly, the mold top assembly is an effective, safe, inexpensive,and efficient device that achieves all the enumerated objectives of theinvention, provides for eliminating difficulties encountered with priorart devices, systems, and methods, and solves problems and obtains newresults in the art.

In the foregoing description, certain terms have been used for brevity,clearness, and understanding; but no unnecessary limitations are to beimplied therefrom beyond the requirement of the prior art, because suchterms are used for descriptive purposes and are intended to be broadlyconstrued.

Moreover, the description and illustration of the invention is by way ofexample, and the scope of the invention is not limited to the exactdetails shown or described.

Having now described the features, discoveries, and principles of theinvention, the manner in which the mold top assembly is constructed andused, the characteristics of the construction, and the advantageous newand useful results obtained; the new and useful structures, devices,elements, arrangement, parts, combinations, and methods are set forth inthe appended claims.

1. An ingot mold top comprising: a base having a pair of side walls,each side wall having a first end and a second end, each of the firstends terminating in an angled portion and the second ends connected by afirst end wall; a wedge having an end wall and a pair of side walls, thepair of side walls extending generally perpendicularly away from the endwall; and, wherein the wedge pair of side walls each terminate in anangled portion and the base and wedge completely encompass an interiorperiphery of a mold.
 2. The ingot mold top of claim 1 wherein the baseside walls and first end wall are a single component and the wedge pairof side walls and end wall are a single component.
 3. The ingot mold topof claim 1 wherein the base angled portions are complimentary shaped tothe wedge side walls angled portions.
 4. The ingot mold top of claim 1wherein the base angled portions and the wedge angled portions each havean angle in a range between 5 degrees and 45 degrees.
 5. The ingot moldtop of claim 1 wherein the wedge end wall locates the base within themold.
 6. The ingot mold top of claim 1 wherein the base side walls andfirst end wall define a ledge integral to the interior periphery.
 7. Theingot mold top of claim 1 wherein the base side walls and first end walldefine a shoulder integral to the exterior periphery.
 8. The ingot moldtop of claim 1 wherein the base is taller than the wedge.
 9. The ingotmold top of claim 1 further comprising a lid complimentary shaped withthe base.
 10. The ingot mold top of claim 6 wherein a lid slides alongthe ledge during installation.
 11. The ingot mold top of claim 1 whereinthe first end wall opposes the wedge end wall.
 12. A method ofinstalling an ingot mold top comprising the steps of: inserting a moldtop base having a pair of side walls with angled terminating portionswithin a mold; locating a mold top wedge at least partially between thebase and the mold; and, forcing the wedge downwards to provide axialmovement in a direction along the angled terminating portions.
 13. Themethod of claim 12 further comprising the step of aligning the baseangled terminating portions with the wedge.
 14. The method of claim 12further comprising the step of locating an installation device proximatethe wedge before the step of forcing the wedge downwards to provideaxial movement in a direction along the angled termination portions. 15.The method of claim 12 further comprising the step of forcing the baseaxially in a direction opposite the wedge by providing the downwardforce on the wedge.
 16. The method of claim 12 further comprising thestep of positioning a lid at least partially on a shoulder of the moldtop base.
 17. The method of claim 16 further comprising the step ofsliding the lid along the shoulder to completely cover the moltenmaterial.
 18. The method of claim 12 further comprising the step ofpositioning the base along substantially three walls of an interiorperiphery of the mold before the step of locating a mold top end wall atleast partially between the base and the mold.
 19. The method of claim12 further comprising the step of locating the mold top wedge withoutstanding over the mold.
 20. The method of claim 12 further comprisingthe step of forcing the mold top wedge downwards to provide axialmovement in a direction along the angled terminating portions withoutstanding over the mold.